Channel anchor

ABSTRACT

A channel anchor for embedding into masonry structures, the channel anchor having an anchor channel and a plurality of anchor shafts attached thereto, with the anchor shaft having a shaft-like structure with an elongated center shank having two ends, a head on one end and a base on the other end, and the anchor shaft being welded to the anchor channel by welding the base of the anchor shaft to the back of the anchor channel.

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention relates generally to construction materials andmethods. More particularly, this invention relates to channel anchorsfor use in structural materials, including concrete, to secure objectsor fixtures to each other or to structural supports or other structures.This invention further relates generally to a method for manufacturingsuch a channel anchor.

2. Prior Art

Concrete structures, such as prefabricated barriers or panels, areubiquitous in the construction industry. As these structures are veryheavy, such structures must be positioned through the use of heavyequipment such as a crane. In order to facilitate positioning, anchors,such as channel anchors, are installed in the concrete structures so asto provide a means to releasably attach or connect such structures toeach other or to other structures. Typically, the anchors are embeddedinto the concrete structures at the time of pouring and curing of theconcrete; however, the anchors also can be retrofitted into the concretestructures by epoxying the anchors into cutouts or slots in the concretestructures.

U.S. Pat. No. 5,729,951 to Frohlich discloses an anchor device for theconstruction industry that is in common use. The Frohlich '951 devicehas an anchor rail that is a C-shaped channel with a hollow interior.The anchor rail has legs connected to a back, with the legs havingangled free ends pointing toward one another and delimiting therebetweena longitudinal slot. Anchors are connected to the anchor rail byinserting the anchors into conical openings in the anchor rail such thatan end of the anchor extends into the hollow interior of the anchorrail, and then swaging the end of the anchor extending into the hollowinterior of the anchor rail. The swaging causes plastic materialdeformation of the end of the anchor and often of the conical opening ofthe anchor rail. The swaged end of the anchor cooperates with theconical opening in the anchor rail to secure the anchor to the anchorrail.

Although the Frohlich '951 device is suitable for many applications, theuse of a swaging attachment technique has drawbacks. First, the swagedend of the anchor defines a weak point in the anchor. The swaged portionof the anchor and the transition portion between the swaged portion andthe anchor shaft (that is, the portions of the anchor that haveundergone plastic deformation) often are weaker than the unswagedremainder of the anchor. Second, a portion of the conical opening oftenundergoes plastic deformation as well, and the portion of the anchorrail that has undergone plastic deformation also defines a weak point inthe anchor rail. Likewise, the transition portion between the portion ofthe anchor rail that has undergone plastic deformation and the remainderof the anchor rail often is weaker than the remainder of the anchorrail. Third, the end of the anchor extending into the hollow interior ofthe anchor rail may not be swaged flush with the interior surface of theback of the anchor rail, possibly leaving bumps and valleys that caninterfere with connectors inserted into the anchor rail. Fourth,improperly swaged anchors may be or become loose within the anchor rail.Fifth, the swaged joints or connections typically have a strengthapproximately 40% less than welded joints.

Accordingly, there is always need for an improved channel anchor for usein the construction industry. For example, there is a need for animproved channel anchor having fewer or no weak points, or with weakpoints that are relatively strong compared to prior art devices. Such achannel anchor also should have a relatively simple structure and berelatively inexpensive to manufacture. Further, such channel anchorsshould be able to be embedded securely into concrete structures suchthat the anchor may resist forces applied to the anchors duringpositioning. It is to these needs, among others, that the presentinvention is directed.

BRIEF SUMMARY OF THE INVENTION

Briefly, the present invention is a channel anchor that may be embeddedinto masonry structures such as concrete panels and barriers. Thechannel anchor comprises an anchor channel (sometimes referred to as ananchor rail) and one or more anchor shafts attached thereto. The anchorchannel is a generally C-shaped channel, preferably manufactured from ahigh strength material such as steel. Each anchor shaft comprises ashank having an enlarged head at one end and an enlarged base at theother, opposite end. The anchor shafts are welded to the back (theexterior surface of the back) of the anchor channel so that each anchorshaft extends perpendicularly from the back of the anchor channel.

The anchor channel is more or less typical of anchor channels with theimportant exception that the anchor channel does not have any receivingopenings. Specifically, unlike the prior art, the back of the anchorchannel does not have any receiving openings through which the anchorsor any other devices may extend. Thus, the anchor channel is a generallyuniform uninterrupted structure and therefore has a greater strengththan a non-uniform interrupted structure. Preferably, the anchor channelis cold-rolled or formed from a piece of sheet material, such as sheetsteel or other material.

The anchor shafts are shaft-like structures having an elongated centershank having two ends, a head on one end and a base on the other end.Preferably, the anchor is manufactured from a single piece of material,with the head and base bring formed from the ends of the center shank.Alternatively, the head and base can be separate structures welded orotherwise attached to the ends of a rod-like center shank. However, ithas been found that manufacturing the anchor from a single piece ofmaterial results in a stronger anchor than manufacturing an anchor fromtwo or more separate pieces.

The center shank typically is a cylindrical rod with a circular crosssection, but may be any elongated shaft with any cross section, such astriangular, square, pentagonal or any other polygonal or non-polygonalcross section. The center shank assists in anchoring the device within aconcrete or other material structure, and typically has a length(measured axially) between approximately 25 millimeters inch and 300millimeters. Preferably, the center shank has a length of betweenapproximately 50 millimeters and 150 millimeters, with betweenapproximately 50 millimeters and 100 millimeters being most preferred.Preferably, the center shank has a diameter of between 6 millimeters and25 millimeters, with between approximately 6 millimeters and 18millimeters being more preferred, and between approximately 10millimeters and 18 millimeters being most preferred. The length anddiameter of the center shank can be selected based on the applicationand one of ordinary skill in the art can select the length and diameterof the center shank without undue experimentation.

The head assists in anchoring the device within a concrete or othermaterial structure, and typically is an enlarged portion of the centershank having a diameter (or the equivalent for non-circular crosssection center shanks) greater than that of the center shank and alength (measured axially to the center shank) between approximately 3millimeters and 25 millimeters. Preferably, the head has a length ofbetween approximately 3 millimeters and 15 millimeters, with betweenapproximately 3 millimeters and 8 millimeters being preferred, and adiameter of between 1.25 and 3 times the diameter of the center shank,with approximately 2 times the diameter of the center shank beingpreferred. The length and diameter of the head can be selected based onthe application and one of ordinary skill in the art can select thelength and diameter of the head without undue experimentation.

The base is used to secure the anchor to the anchor channel, and alsotypically is an enlarged portion of the center shank having a diameter(or the equivalent for non-circular cross section center shanks) greaterthan that of the center shank and a length (measured axially to thecenter shank) between approximately 3 millimeters and 25 millimeters.Preferably, the base has a length of between approximately 3 millimetersand 15 millimeters, with between approximately 3 millimeters and 8millimeters being preferred, and a diameter of between 1.25 and 3 timesthe diameter of the center shank, with approximately 2 times thediameter of the center shank being preferred. The length and diameter ofthe base can be selected based on the application and one of ordinaryskill in the art can select the length and diameter of the base withoutundue experimentation.

The anchor shafts are mounted on the anchor channel by welding so thatthe base acts as a mounting base and is welded to the back (the exteriorsurface of the back) of the anchor channel. The strength of the weldmentbond between the anchor shaft and the anchor channel generally isgreater that a swaged bond, and often is in the range of 100 kN or more.Further, the combination of a lack of receiving openings in the anchorchannel and using welding to bond the anchor to the anchor channelresults in a stronger device.

The anchor shafts can be mounted upon the anchor channel withoutsubstantially deforming the continuous back of the anchor channel. Thatis, the anchor shafts may be mounted upon the anchor channel such thatthe back interior surface of the back of the anchor channel isessentially and continuous flat. Preferably, the back interior surfaceof the back of the anchor channel remains a continuous flat surface andis not deformed during the bonding of the anchor shafts to the exteriorsurface of the back of the anchor channel. The essentially flatstructure reduces the friction and catching that can occur wheninserting a connecting device within the hollow interior of the anchorchannel. Further, the essentially flat exterior surface maximizes thestrength of the weldments between the anchor and the anchor channel andthe overall strength of the channel anchor particularly along the anchorchannel in the positions corresponding to the anchor shafts.

In use and application, the channel anchor may be embedded or cast intoa masonry structure. In one embodiment, the anchor shafts of the channelanchor are placed into the wet material (that is, the uncured concreteor other masonry material, or other suitable materials such as epoxies,carbon fiber materials, graphite fiber materials, ceramics, and thelike) such that a cast forms around the anchor shafts. In anotherembodiment, a hole or slot is drilled into the masonry structure (forease of understanding, all structures for which the channel anchor canbe used will be referred to as a masonry structure irrespective of theactual material of manufacture), a construction epoxy is filled therein,and the anchor shafts of the channel anchor are then inserted therein.In another embodiment, the channel anchor is positioned within a mold ofa masonry structure and the masonry material is poured into the moldsuch that the mold is filled and the wet material forms a cast aroundthe anchor shafts. After the material has set and cured, the anchorshafts are secured in place within the masonry structure.

Another aspect of the invention is a method for manufacturing thechannel anchor. In one embodiment, this method for manufacturing thechannel anchor comprises the steps of:

(1) providing an anchor channel having a substantially flat back andside arms extending generally normal to the top and then turning inwardtowards each other so as to form a longitudinal slot opposite the back;

(2) providing a plurality of anchor shafts each having a head and amounting base;

(3) placing and positioning the anchor shafts on the anchor channel suchthat the mounting base contacts the back of the anchor channelapproximately mid-width; and

(4) welding the mounting base to the back of the anchor channel.Preferably, the anchor channel is not interrupted or deformedsubstantially during the welding process. Once the welding has cooledand cured, the channel anchor is preferably unitary with the materialfused into a single unit.

These features, and other features and advantages of the presentinvention, will become more apparent to those of ordinary skill in therelevant art when the following detailed description of the preferredembodiments is read in conjunction with the appended drawings in whichlike reference numerals represent like components throughout the severalviews.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one embodiment of the channel anchor ofthe present invention.

FIG. 2A is a cross section of one embodiment of an anchor channelcompatible with the channel anchor of the present invention.

FIG. 2B is a cross section of another embodiment of an anchor channelcompatible with the channel anchor of the present invention.

FIG. 3 is a side view of one embodiment of the anchor shaft of thechannel anchor shown in FIG. 1.

FIG. 4 is a sectional side view of the channel anchor taken along theline 4′-4′ of FIG. 1.

FIG. 5 is top view of the channel anchor shown in FIG. 1.

FIG. 6 is a cutaway side view showing the channel anchor embedded in amasonry structure.

FIG. 7 is a cutaway side view showing the channel anchor in a masonrystructure held in place using an epoxy resin.

DETAILED DESCRIPTION OF THE PREFERRED

Illustrative embodiments of the present invention include a channelanchor that may be embedded into masonry structures and structures ofother materials, such as but not limited to concrete and cementbarriers, concrete and cement panels, and prefabricated panels andbarriers. The channel anchor of the present invention is usefulparticularly with masonry structures that are positioned usingmechanical means and with structures that attach to similar or to otherstructures. While the invention is described herein in conjunction withthe preferred and illustrative embodiments, it will be understood thatthe invention is not limited to these embodiments.

Referring now to the figures in general, the figures illustratepreferred embodiments of the invention in the best mode known to theinventor at this time. Specifically, FIG. 1 is a perspective view of oneembodiment of the channel anchor 10 of the present invention in finishedform. FIG. 2A is a cross section of a preferred embodiment of an anchorchannel 30 and FIG. 2B is a cross section of an alternative embodimentof an anchor channel 30 compatible with the channel anchor 10 of thepresent invention. FIG. 3 is a side view of one embodiment of the anchorshaft 20 of the present invention. FIG. 4 is a sectional side view ofthe channel anchor 10 showing the unitary structure of the anchor shaft20 and the preferred weldment 50 design. FIG. 5 is top view of thechannel anchor 10 illustrating the preferred location of the anchorshafts 20 on the anchor channel 30. FIG. 6 is a cutaway side viewshowing the channel anchor 10 embedded in a masonry structure 100. FIG.7 is a cutaway side view showing the channel anchor 10 in a masonrystructure 100 held in place using an epoxy resin 101.

Referring now to FIG. 1, an embodiment of a channel anchor 10 inaccordance with this invention comprises an anchor channel 30 and aplurality of anchor shafts 20 attached thereto. The anchor channel 30 isa generally C-shaped channel, preferably manufactured from a highstrength material such as steel. Each anchor shaft 20 comprises a shank24 having enlarged head 22 at one end and an enlarged base 40 at theother, opposite end. The anchor shafts 20 are welded to back 32 (theexterior surface of the back) of the anchor channel 30 so that eachanchor shaft 20 extends perpendicularly from the back 32 of the anchorchannel 30. Preferably, the plurality of anchor shafts 20 are arrangedin the center (mid-width) of the anchor channel 30 and are arrangedequidistant from each of their respective ends 31 of the anchor channel30. Opposite the side where the anchor shafts 20 are attached is alongitudinal channel 38 that may be anchored to another structure.

Referring now to FIGS. 2A and 2B, sectional side views of the anchorchannel 30 show that anchor channel 30 is comprised of a back 32, sidefaces 34, and edges 42. The anchor channel 30 is more or less typical ofknown anchor channels with the important exception that the anchorchannel 30 does not have any receiving openings. Specifically, unlikethe prior art, the back 32 of the anchor channel does not have anyreceiving openings through which the anchors 20 or any other devices mayextend. Thus, the anchor channel 30 is a generally uniform uninterruptedstructure and therefore has a greater strength than a non-uniforminterrupted structure. Preferably, the anchor channel 30 is cold-rolledor formed from a piece of sheet material, such as sheet steel or othermaterial.

The shape of the anchor channel 30 defines a hollow interior orlongitudinal channel 38 with edges 50. Essentially, the longitudinalchannel 38 is formed by the ends 42 of the anchor channel 30 andprovides a means for interconnecting the anchor channel 30 with aconnector (not shown). In the embodiment shown in FIG. 2A, the ends 42are angled inward towards the hollow interior of the anchor channel. Inthe embodiment shown in FIG. 2B, the ends 42 are straight such that ends42 extend towards each other.

Referring now to FIG. 3, a side view of one anchor shaft 20 shows thatthe anchor shaft 20 comprises a shank 24 having a first end connected toand integrally formed with a head 22 and a second end on the oppositeend of the shank 24 and connected to and integrally formed with amounting base 40. The anchor shafts 20 are shaft-like structures havingan elongated center shank 24 having two ends, a head 22 on one end and abase 40 on the other end. Preferably, the anchor is manufactured from asingle piece of material, with the head 22 and base 40 bring formed fromthe ends of the center shank 24. Alternatively, the head 22 and base 40can be separate structures welded or otherwise attached to the ends of arod-like center shank 24. However, it has been found that manufacturingthe anchor 20 from a single piece of material results in a strongeranchor 20 than manufacturing an anchor 20 from two or more separatepieces.

The center shank 24 typically is a cylindrical rod with a circular crosssection, but may be any elongated shaft with any cross section, such astriangular, square, pentagonal or any other polygonal or non-polygonalcross section. The center shank 24 assists in anchoring the devicewithin a concrete or other material structure 100, and typically has alength (measured axially) between approximately 25 millimeters and 300millimeters. Preferably, the center shank 24 has a length of betweenapproximately 50 millimeters and 150 millimeters, with betweenapproximately 50 millimeters and 100 millimeters being most preferred.Preferably, the center shank 24 has a diameter of between 6 millimetersand 25 millimeters, with between approximately 6 millimeters and 18millimeters being more preferred, and between approximately 10millimeters and 18 millimeters being most preferred. The length anddiameter of the center shank 24 can be selected based on the applicationand one of ordinary skill in the art can select the length and diameterof the center shank 24 without undue experimentation.

The head 22 assists in anchoring the device 10 within a concrete orother material structure 100, and typically is an enlarged portion ofthe center shank 24 having a diameter (or the equivalent fornon-circular cross section center shanks 24) greater than that of thecenter shank 24 and a length (measured axially to the center shank 24)between approximately 3 millimeters and 25 millimeters. Preferably, thehead 22 has a length of between approximately 3 millimeters and 15millimeters, with between approximately 3 millimeters and 8 millimetersbeing preferred, and a diameter of between 1.25 and 3 times the diameterof the center shank 24, with approximately 2 times the diameter of thecenter shank 24 being preferred. The length and diameter of the head 22can be selected based on the application and one of ordinary skill inthe art can select the length and diameter of the head 22 without undueexperimentation.

The base 40 is used to secure the anchor shaft 20 to the anchor channel30, and also typically is an enlarged portion of the center shank 24similar to the head 22 and having a diameter (or the equivalent fornon-circular cross section center shanks 24) greater than that of thecenter shank 24 and a length (measured axially to the center shank 24)between approximately 3 millimeters and 25 millimeters. Preferably, thebase 40 has a length of between approximately 3 millimeters and 15millimeters, with between approximately 3 millimeters and 8 millimetersbeing preferred, and a diameter of between 1.25 and 3 times the diameterof the center shank 24, with approximately 2 times the diameter of thecenter shank 24 being preferred. The length and diameter of the base 40can be selected based on the application and one of ordinary skill inthe art can select the length and diameter of the base 40 without undueexperimentation.

The base 40 also can be analogized to a wafer, coin or disc shapedstructure having two opposing flat surfaces, a thickness (the lengthdisclosed above), and a perimeter. One of the opposing flat surfaces isattached to the center shank 24 (it preferably is an extension of thecenter shank 24) and the other of the opposing flat surfaces is placedagainst the back 32 of the anchor channel 30. The weldment 52 is madeabout the perimeter of the base 40 thus welding the base 40 to the back32. As disclosed previously, the base 40 can be any shape such as acircle, oval, polygon or non-polygon, and the terms wafer, coin or discare used only for illustration.

Referring now to FIG. 4, anchor shaft 20 is welded onto anchor channel30 so that the mounting base 40 is welded to the back 32 of the anchorchannel 30. The anchor shafts 20 are mounted on the anchor channel 30 bywelding so that the base 40 acts as a mounting base and is welded to theback 32 (the exterior surface of the back) of the anchor channel 30. Thestrength of the weldment 50 bond between the anchor shaft 20 and theanchor channel 30 generally is greater that a swaged bond, and often isin the range of 100 kN or more. Further, the combination of a lack ofreceiving openings in the anchor channel 30 and using welding to bondthe anchor shafts 20 to the anchor channel 30 results in a strongerdevice 10.

The anchor shafts 20 can be mounted upon the anchor channel 30 withoutsubstantially deforming the back 32. That is, the anchor shafts 20 maybe mounted upon the anchor channel 30 such that the back 32 isessentially flat. Preferably, the back of the anchor channel 30 remainsa continuous flat surface and is not deformed during the bonding of theanchor shafts 20 thereto. The essentially flat structure maximizes thestrength of the bond between the anchor channel 30 and the anchor shafts20. More importantly, the essentially flat back 32 maximizes thestrength of the channel anchor 10 particularly along the anchor channel30 in the positions corresponding to the anchor shafts 20.

As disclosed previously, the length of the base 40 can be chosen withincertain economic parameters. Specifically, the length of the base 40should be large enough such that the weldment 50 attaches the base 40,and thus the anchor shaft 20, to the anchor channel 30 with sufficientstrength such that the anchor channel 30 will not separate from theanchor shafts 20 under the desired operating load. For lower loadsituations, the height of the base 40 can be smaller and for higher loadsituations, the height of the base 40 can be larger. It has been foundthat using a base 40 height of between approximately 3 millimeters and 8millimeters and a base 40 diameter of approximately 25 millimeters andwelding the base 40 to the anchor channel 30 in a common manner providesa weldments 42 strength of up to 100 kN or more, which is suitable formost common situations of connecting concrete structures.

Referring now to FIG. 5, a top view of the anchor shafts 20 mounted onan anchor channel 30 shows that head 22 extends radially outward aboutthe edge of the shank 24. When the head 22 is embedded in the masonrystructure 100, the head 22 can serve to distribute the weight and cancreate the resistance to the concrete 100 to prevent the channel anchor10 from being pulled out. Hence, it is possible to create additionalresistance by using a larger head 22. One of ordinary skill in the artmay the dimensions of the head 22 for optimal resistance within themasonry structure 100 without undue experimentation.

FIG. 5 also shows preferred locations for the anchor shafts 20 on theanchor channel 30. Specifically, when using two anchor shafts 20 peranchor channel 30, the anchor shafts 20 preferably are mounted mid-widthon the anchor channel between one-fifth and one-third the length of theanchor channel 30 in from the edges 31, and more preferablyapproximately one-fourth the length of the anchor channel 30 in from theedges 31.

Referring now to FIG. 6, the channel anchor 10 may be embedded into amasonry structure 100. In one embodiment, the anchor head 22 extends ina direction perpendicular to a pulling force applied to the anchorchannel 30 so as to assist in preventing the channel anchor 10 frombeing pulled out of the surrounding material. In this embodiment, theanchor shafts 20 are embedded in a masonry structure 100 by castingmasonry structure 100 around the anchor shafts 20. Preferably, themasonry structure 100 is molded such that the anchor shafts 20,including the head 22, are immobilized in the masonry structure 100. Forexample, the masonry material may be poured into a mold or frame so thatthe masonry material flows around the anchor shafts 20 and around thehead 22 so as to the secure the anchor shafts 20 into the masonrystructure 100. Hence, the anchor heads 22 provide effective resistanceagainst pulling the channel anchor 10 from a masonry structure 100.

FIG. 6 also shows an alternative structure of the center shank 24. Inthis alternative structure, the outer surface of center shank 24 ispatterned with protrusions 54 or dimples 56. The use of protrusions 54or dimples 56 provides additional holding force for the anchor shafts 20within the masonry structure 100. As an analogy, protrusions 54 ordimples 56 act much like the protrusions on reinforcing bar (rebar) usedfor concrete structures such as roads and buildings.

Referring now to FIG. 7, the channel anchor 10 is shown mounted in aslot 104 or other opening in a masonry structure 100. A slot 104 of aradius (or other shape depending on the shape of the anchor shaft 24 orthe tool used to create the slot 104) larger than of the anchor shaft 20and spaced according to the channel anchor 10 are drilled or otherwiseformed into the masonry structure 100. After the debris and anyextraneous material are removed, an injection gun may be used to injecta construction epoxy 101 into the slot 104. The anchor shafts 20 of thechannel anchor 10 are inserted then into the slot 104 such that the back32 rests against the masonry structure 100. The construction epoxy 101surrounds anchor shafts 20 once the channel anchor 10 is in place. Afterthe construction epoxy 101 has set and cured, the anchor shafts 20 aresecured in place within the masonry structure 100. This method ofinstallation provides a means for installing the channel anchor 10 intomasonry structure 100 that has previously set.

Another aspect of the invention is a method for manufacturing thechannel anchor. In one embodiment, a method for manufacturing thechannel anchor 10 comprises the steps of:

(1) providing an anchor channel 30 having a substantially flat back 32and side arms 42 extending generally normal to the back 32 and thenturning inward towards each other so as to form a longitudinal slot 38opposite the back 32;

(2) providing a plurality of anchor shafts 20 each having a head 22 anda mounting base 40;

(3) placing and positioning the anchor shafts 20 on the anchor channel30 such that the mounting base 40 is up against the back 32 of theanchor channel 30; and

(4) welding the mounting base 40 to the back 32 of the anchor channel30.

Preferably, the anchor channel 30 is not interrupted or deformedsubstantially during the welding process. Once the weldment 52 hascooled and cured, the channel anchor 10 is preferably unitary with thematerial fused into a single unit.

The channel anchor 10 may be manufactured from a suitable metal or othermaterial. For example, the anchor shafts 20 may be machined, forged orcast from a steel bar stock. Likewise, the anchor channel 30 may be coldrolled from a steel bar stock. Another suitable metal is zinc-platedsteel. As welding is the preferred method for joining the anchor shafts20 and the anchor channel 30, it is preferred that the anchor shafts 20and the anchor channel 30 be manufactured of the same metal. The qualityof steel suitable with the channel anchor 10 may be selected accordingto the load bearing forces upon the channel anchor 10. One of ordinaryskill in the art may select a suitable material without undueexperimentation.

The dimensions of the channel anchor 10 may be dependent on the designedload requirements of a particular application. However, the dimensionsmay depend on factors such as size of the connectors, the size of themasonry structure 100, and the material selected for the channel anchor10. One of ordinary skill in the art may select appropriate dimensionsfor the channel anchor 10 and components thereof.

As disclosed previously, in use and application, the channel anchor 10may be embedded or cast into a masonry structure 100. In one embodiment,the anchor shafts 20 of the channel anchor are placed into the wetmaterial (that is, the uncured concrete or other masonry material, orother suitable materials such as epoxies, carbon fiber materials,graphite fiber materials, ceramics, and the like) such that a cast formsaround the anchor shafts 20. In another embodiment, a hole or slot 104is drilled into the masonry structure 100 (as mentioned previously, forease of understanding, all structures for which the channel anchor 10can be used will be referred to as a masonry structure 100 irrespectiveof the actual material of manufacture), a construction epoxy 101 isfilled therein, and the anchor shafts 20 of the channel anchor 10 arethen inserted therein. In another embodiment, the channel anchor 10 ispositioned within a mold of a masonry structure 100 and the masonrymaterial is poured into the mold such that the mold is filled and thewet material forms a cast around the anchor shafts 20. After thematerial has set and cured, the anchor shafts 20 are secured in placewithin the masonry structure 100.

The channel anchor 10 may be used with or embedded in any masonrystructure 100 including concrete structures. For example, such concretestructures may include prefabricated panels or barriers. Such masonrystructures 100 include concrete barriers or concrete blocks. Further,the channel anchor 10 may be used with or embedded in prefabricatedwalls and construction panels. Masonry structures 100 suitable with thisinvention are obvious to those with ordinary skill in the art.

The above detailed description of the preferred embodiments, examples,and the appended figures are for illustrative purposes only and are notintended to limit the scope and spirit of the invention, and itsequivalents, as defined by the appended claims. One skilled in the artwill recognize that many variations can be made to the inventiondisclosed in this specification without departing from the scope andspirit of the invention.

1. A channel anchor comprising: a) an anchor channel having a generallyC-shaped channel having a back, two side and two ends, wherein the backdoes not have any receiving openings resulting in a generally uniformuninterrupted structure; and b) at least one anchor shaft welded to theanchor channel, wherein the anchor shaft is a shaft-like structurehaving an elongated center shank having two ends, a head on one end anda base on the other end, and the anchor shaft is welded to the anchorchannel by welding the base of the anchor shaft to the back of theanchor channel.
 2. The channel anchor as claimed in claim 1, wherein thecenter shank is an elongated shaft having a length measured axiallybetween approximately 25 millimeters and 300 millimeters and a diameterof between 8 millimeters and 25 millimeters.
 3. The channel anchor asclaimed in claim 2, wherein the center shank has a length of betweenapproximately 50 millimeters and 150 millimeters and a diameter ofbetween approximately 8 millimeters and 18 millimeters.
 4. The channelanchor as claimed in claim 2, wherein the center shank has a length ofbetween approximately 50 millimeters and 100 millimeters and a diameterof between approximately 10 millimeters and 18 millimeters.
 5. Thechannel anchor as claimed in claim 1, wherein the head is an enlargedportion of the center shank having a diameter greater than that of thecenter shank and a length between approximately 3 millimeters and 25millimeters.
 6. The channel anchor as claimed in claim 5, wherein thehead has a length of between approximately 3 millimeters and 15millimeters and a diameter of between 1.25 and 3 times the diameter ofthe center shank.
 7. The channel anchor as claimed in claim 6, whereinthe head has a length of between approximately 3 millimeters and 8millimeters and a diameter of approximately 2 times the diameter of thecenter shank.
 8. The channel anchor as claimed in claim 2, wherein thebase is an enlarged portion of the center shank having a diametergreater than that of the center shank and a length between approximately3 millimeters and 25 millimeters.
 9. The channel anchor as claimed inclaim 8, wherein the base has a length of between approximately 3millimeters and 15 millimeters and a diameter of between 1.25 and 3times the diameter of the center shank.
 10. The channel anchor asclaimed in claim 9, wherein the base has a length of betweenapproximately 3 millimeters and 8 millimeters and a diameter ofapproximately 2 times the diameter of the center shank.
 11. The channelanchor as claimed in claim 1, wherein the back of the anchor channel isa continuous and substantially flat surface and the base comprises twoopposing flat surfaces, a thickness, and a perimeter, one of theopposing flat surfaces of the base is attached to the center shank andthe other of the opposing flat surfaces of the base is placed againstthe back of the anchor channel, and a weldment is made about theperimeter of the base thus welding the base to the back.
 12. The channelanchor as claimed in claim 11, wherein the anchor shaft is bondedperpendicular to the back of the anchor channel.
 13. The channel anchoras claimed in claim 1, wherein the anchor channel has a hollow interiordefining a longitudinal slot.
 14. The channel anchor as claimed in claim13, wherein the two ends form the longitudinal slot.
 15. The channelanchor as claimed in claim 1, wherein the anchor channel and the anchorshaft are made from the same material.
 16. The channel anchor as claimedin claim 12, wherein the anchor supports a force greater than 50 kN. 17.The channel anchor as claimed in claim 1, wherein the cross sectionalarea of the base is greater than the cross sectional area of the shank.18. The channel anchor as claimed in claim 1, wherein the crosssectional area of the head is greater than the cross sectional area ofthe shank.
 19. A method for manufacturing a channel anchor comprisingthe steps of: a) providing an anchor channel having a substantially flatback and side arms extending generally normal to the top and thenturning inward towards each other so as to form a longitudinal slotopposite the back; b) providing a plurality of anchor shafts each havinga head, a center shank and a mounting base, wherein the base comprisestwo opposing flat surfaces, a thickness, and a perimeter; c) placing andpositioning the anchor shafts on the anchor channel such that themounting base contacts the back of the anchor channel approximatelymid-width, whereby one of the opposing flat surfaces of the base isattached to the center shank and the other of the opposing flat surfacesis placed against the back of the anchor channel; and d) welding themounting base to the back of the anchor channel such that a weldment ismade about the perimeter of the base thus welding the base to the back,wherein the anchor channel is not interrupted or deformed substantiallyduring the welding process and once the weldment has cooled and cured,the channel anchor is a unitary structure.
 20. The method as claimed inclaim 19, wherein the anchor channel has a continuous and substantiallyflat back and the anchor shaft is bonded to back.
 21. The method asclaimed in claim 20, wherein the anchor channel remains continuousduring the welding of the base to the anchor channel.
 22. An improvedchannel anchor comprising at least one anchor shaft and an anchorchannel, the improvement comprising an anchor shaft having a shaft-likestructure with an elongated center shank having two ends, a head on oneend and a base on the other end, and the anchor shaft being welded tothe anchor channel by welding the base of the anchor shaft to the backof the anchor channel, wherein the base comprises two opposing flatsurfaces, a thickness, and a perimeter, and one of the opposing flatsurfaces is attached to the center shank.
 23. The improved channelanchor as claimed in claim 22, wherein the center shank is an elongatedshaft having a length measured axially between approximately 25millimeters and 300 millimeters and a diameter of between 6 millimetersand 25 millimeters.
 24. The improved channel anchor as claimed in claim23, wherein the head is an enlarged portion of the center shank having adiameter greater than that of the center shank and a length betweenapproximately 3 millimeters and 25 millimeters.
 25. The improved channelanchor as claimed in claim 24, wherein the base is an enlarged portionof the center shank having a diameter greater than that of the centershank and a length between approximately 3 millimeters and 25millimeters.